nextGeneration II 2x7-280, 14-280, 14-350 - Schulze Elektronik GmbH

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4 Page Issue 03.10 Operating instructions Issue 03.10, page nextGeneration II Firmware version V 1.00 and higher nextGeneration II Firmware V 1.00 and higher 45 • Protect the charger from direct exposure to the sun (the sun´s heat may temporarily turn the LCdisplay black), dust, moisture and rain(!). Even though the schulze chargers are smart (they are micro-processor equipped and can determine a battery’s number of cells and its optimum charge current pattern), attempting to charge the following packs should not be attempted: • batteries built up from cells of different types and capacities • batteries made from different types of single cells • batteries with a different charging level of the cells • non rechargeable cells (dry cells) • batteries which are not expressly designed for fast charging and recharging. • defective or damaged packs or cells • already fully charged and/or hot batteries • battery packs with internal charge-current limiting devices (not valid for Schulze LiPoTx und LiPoRx) • batteries which are buildt-in (internal) to other equipment Do not exceed a battery’s design (maximum) charge current as specified by its manufacturer; note that the schulze chargers will still optimally charge these packs in automatic charging mode; you can program the charger’s max (limit) charge current. • Please bear in mind that new rechargeable batteries do not achieve their full capacity until they have completed several charge / discharge cycles. New batteries generally, and deep-discharged Nickel batteries in particular, may cause premature charge termination. For this reason it is absolutely essential to check that the automatic charge cut-off circuit works correctly and reliably; this is achieved by carrying out several test-charges, and checking the quantity of capacity charged into the pack. When charging battery packs with less than 4 nickel cells, exercise extra care to make sure that these are not over-charged (especially when you use less than the specified current for this battery type - see chapter 4). Packs which are (too) deeply discharged may cause the charger to cut off too soon. New batteries will only achieve their maximum capacity after several charge/discharge cycles; schulze chargers can be programmed to provide these cycles automatically. Please remember that battery packs can heat up considerably especially during multiple charge/discharge cycles; program your charger’s max discharge current to prevent overheating of the packs unless you provide additional cooling (some of the racing pilots use a tube with electric fan cooling!). Note that packs with low capacity will dangerously overheat at high discharge currents; the schulze charger can (and) should in this case be programmed to the limit discharge rate to a more acceptable level, for instance 1C and/or a battery cooler in combination with the temperature sensor for cut-off must be used. You can also use our build in low-temperature-start circuit. (Do not forget to activate temperature sensor to the right pack output and fix it at the right battery.) • Safety hint: Always verify the charge amount which your battery has absorbed (mAh or Ah) after a full charge (this is indicated on the display panel); this is probably the best gauge of a battery’s health and/or the proper operation of the charger. This way, you will avoid unexpected loss of power and/or control. An additional important function is the selection of the automatic cut-off circuit. Read the important comments in Chapter 12). Maximum protection against malfunctions of the cut-off automatic is provided by selecting additional cut-off criterias like max. temperature, max. energy input and max. charge time. For trouble-free operation, please check … … that the ferrite ring in the charge lead does not fracture. The ring prevents the charge lead acting as an aerial, i.e. radiating the pulsed frequency of the voltage converter and the processor in an unacceptable way. It is absolutely essential if the charger is to operate in the manner required for CE approval. … that the charge leads used for the Battery 1 and 2 outputs are as short as possible. The maximum total cable length - from the sockets to the battery - should be no longer than 70 cm. Twist the wires together to help suppress interference. … that the charge lead for charge output 1 is wound through one of the ferrite CE rings at least four times. These rings are probably familiar to you from long servo extension leads, albeit in a different size. The ring must be located no more than 5 cm from the banana plugs which are attached to the chargers end of the charge lead. 27.5 Standard Balancing Adapters We offer a selection of printed circuit adapter boards which allow the balancing of 2s-7s (...14s) battery packs which are equipped with the most different balancing connectors. The balancing adapter boards are fitted with a cable containing an 8 pin EH socket - suited for the EH connector of the nextGen.II. 27.5.1 BalAd-Set7 for battery 1 and/or battery 2 Set containing 4 adapter PCBs with different plug systems (EH, XH, PQ, TP) and each with different pin counts to connect 2s ... 7s battery packs. 27.5.2 BalAd-EH7 for battery 1 and/or battery 2 Adapter PCB equipped with 6 EH male connectors of different pin counts to connect 2s ... 7s battery packs 27.5.3 BalAd-XH7 for battery 1 and/or battery 2 Adapter PCB equipped with 6 XH male connectors of different pin counts to connect 2s ... 7s battery packs 27.5.4 BalAd-PQ7 for battery 1 and/or battery 2 Adapter PCB equipped with 6 PQ male connectors of different pin counts to connect 2s ... 7s battery packs 27.5.5 BalAd-TP7 for battery 1 and/or battery 2 Adapter PCB equipped with 4 TP male connectors of different pin counts to connect 2s ... 7s battery packs 27.5.6 BalAd-EH14. For battery 1 use only - due to the fact that all 14 balancing circuits can be used and the second balancing group is no longer available for battery 2. • Adapter PCB equipped with 13 EH male connectors of different pin counts to connect 2s ... 24s battery packs which can be separated into 2 packs. Note: When the packs are combined or equipped with two connectors then it is essential that the pack with the lower cell count (2...7) has to be connected to the balancing output EH1 of the charger - and also with the black ("-") power cable to the charge output 1. 27.6 Schulze Balancinbg Cables The sets are assorted to make 10- and 20-pin. balancing cables which can be coded battery typical - to allow „plug-and-play“ charging of your batteries with modern Schulze chargers. Note: A detailled description of the pinout and the mounting instructions are enclosed in the balancer cable kits (BalCab10 or 20 - Set). BalCab10-Set/BalCab20-Set BalCab10/20-Verlängerung The principle of connection of Schulze Balancers (cell arrangement as the storeys in a high-rise building) + cell 7 (seventh storey)= + battery + cell 6 (sixth storey) = - cell 7 + cell 5 (fifth storey) = - cell 6 + cell 4 (fourth storey) = - cell 5 + cell 3 (third storey) = - cell 4 + cell 2 (second storey)= - cell 3 + cell 1 (first storey) = - cell 2 - cell 1 (ground floor) = earth = - battery
44 Page Issue 03.10 Operating instructions Issue 03.10, page nextGeneration II Firmware version V 1.00 and higher nextGeneration II Firmware V 1.00 and higher 5 27 Balancing and measuring connectors 27.1 The charger contains two balancer connectors which could be used directly (without any adapter). Each balancing connector is equipped with a 8-pin EH-connector (male, white), on which on principle can be connected battery packs up to 7s - when they are plugged in left justified(!). This means that two 2s-7s batteries can be charged and balanced independently from each other at the same time. • Practically you should use separate balancing adapters for each cell types with a collection of connectors for each cell count (see below). • When you connect a battery pack with two balancing connectors or 8 cells or more then both balancing groups are working automatically for output 1. In this way up to 14 LiPo cells in only one pack can be balanced. The charge output 2 can further be used regardless of charge output 1 if it was not coupled to charge output 1. Only the second balancing group is in this case no longer available for output 2. 27.2 Between both EH plugs a 24-pin socket is located for the Schulze adapter boards BalAd-SE4- 7-14 or BalAd-SE4x7. • These boards are assembled with Schulze BalCab male connectors and in addition to it equipped with two EH connectors for the simple reason that the board covers the two connectors on the charger's main board below. Please place the adapter board completely and horizontally so that the board rests fully upon the chargers plastic case. Note: • Do never plug the balancing connectors of different battery packs to those connectors which are electrically joined in parallel. These thereby are causing short circuits and it can happen that the connected battery pack will be damaged. Also the copper leads on the PCB could explode. • Danger of short circuits! Open pins of the electrically joined connectors lead voltage when to one of the connectors a balancing cable is connected! 27.3 Schulze BalAd-SE4-7-14 To avoid short circuits it is essential that you use only one of the different balancing connectors which are assigned to the same battery because they are connected to each other by printed wires! 27.3.1 Battery 1; up to max. 7s: Please use either the left BalCab10 connector (10-pin, black) or the left 8-pin EH connector (white). 27.3.2 Battery 1; up to max. 7s: Please use either the right BalCab10 connector (10-pin, black) or the right 8-pin EH connector (white). 27.3.3 Battery 1+2; up to 14s: When you use the BalCab20 connector in the middle the it is not allowed to use any of the other 4 connectors on the left (27.3.1) and the right (27.3.2). 27.4 Schulze BalAd-SE4x7 To avoid short circuits you may use only one of the different balancing connectors which are assigned to the same battery because they are connected to each other by printed wires! 27.4.4 Battery 1; up to 7s: It is essential that you use either the left BalCab20 socket (20-pin, black) or the left 8-pin EH connector (white). 27.4.5 Battery 2; up to 7s: It is important that you use either the right BalCab20 connector (20-pin, black) or the right 8-pin EH connector (white). 3 Commonly used Terms Final charge voltage: the voltage at which the battery's charge limit (capacity limit) is reached. The charge process switches from a high current to a low maintenance rate (trickle charge) at this point. From this point on further high current charging would cause overheating and eventual terminal damage to the pack. Final discharge voltage: the voltage at which the battery's discharge limit is reached. The chemical composition of the batteries determines the level of this voltage. Below this voltage the battery enters the deep discharge zone. Individual cells within the pack may become reversepolarised in this condition, and this can cause permanent damage. Memory effect: The real memory effect has been recorded by Nasa, caused by repeated charge / discharge cycles. Nasa has found that full capacity can be regained by overcharging the cells. In modelling applications different effects are responsible for the reduction in cell capacity. The problem can be cured by balancing the cells (see below), and prevented by the measures described in Chapter 4.1.3. Battery conditioning: a method of regaining full (nominal) capacity by alternately charging and discharging the pack, sometimes several times. This process is especially useful after a long period of non-usage (e.g. after purchase, or after several weeks without flying), and is also used to disperse the memory effect (see below). The effect of battery conditioning is to break down the coarse crystaline structure (low capacity) inside the cell and convert it into a fine crystaline one (high capacity). Power-On (- reset): the status of the nextGenerationII after it has been connected to the car battery. Ready message: charger ready to run the program you just have selected (batteries not connected). The display shows "ready". C: Coulomb or capacity: Unit of measurement relating to the quantity of charged energy. In conjunction with charge current data this unit is used to determine the recommended / prescribed charge current of a battery of a given capacity. Example: if the charge or discharge current of a 500 mAh battery is 50 mA, we refer to this as a charge or discharge at one tenth C (C/10 or 1/10 C). A, mA: unit of measurement relating to charge or dis-charge current. 1000 mA = 1 A (A=Ampere, mA=Milliampere) Ah, mAh: unit of measurement for the capacity of a battery (Amperes x time unit; h = hour). If a pack is charged for one hour at a current of 2 A, it has been fed 2 Ah of energy. It receives the same quantity of charge (2 Ah) if it is charged for 4 hours at 0.5 A, or 15 minutes (=1/4 h) at 8 A.
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nextGeneration II 2x7-280, 14-280, 14-350 - Schulze Elektronik GmbH

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